Removing sealant around a seal cap

ABSTRACT

A method and apparatus for sealing a fastener element. A structure may be positioned over a seal cap that has been adhered and sealed to the fastener element. A number of projections associated with the structure may be moved along an interface formed between the seal cap and an object in which the fastener element has been installed such that the number of projections removes at least a portion of excess material around the seal cap while moving along the interface between the seal cap and the object.

This application is a divisional of and claims the benefit of priorityto U.S. patent application Ser. No. 13/886,557, filed May 3, 2013, nowU.S. Pat. No. 9,295,367, which claims the benefit of U.S. ProvisionalApplication No. 61/778,389, filed Mar. 12, 2013, the disclosure of whichis incorporated herein in its entirety.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to seal caps and, inparticular, to the installation of seal caps. Still more particularly,the present disclosure relates to a method and apparatus for removingexcess sealant that squeezes out of a seal cap during installation ofthe seal cap.

2. Background

Seal caps may be used to cover and seal fastener elements such as, forexample, without limitation, screws and bolts. Typically, a seal cap maybe installed over a fastener element by applying a sealant materialwithin a cap and then placing the cap over the head of the fastenerelement. In some cases, the cap may be referred to as the seal cap. Inother cases, the cap and the sealant material may together form a sealcap.

During installation, the cap and the sealant material may be presseddown over the fastener element to ensure that the sealant materialadheres to and fully covers the fastener element. However, oftentimes,excess sealant material may squeeze out and around the cap when the capand the sealant material within the cap are placed over the fastenerelement and pressed downwards. The excess sealant material around thecap may be undesirable. For example, without limitation, seal caps maybe used for an object in which multiple fastener elements have beeninstalled. Excess sealant material may reduce the aesthetic appeal ofthe object into which the fastener element has been installed. Further,the excess sealant material may increase the weight of the object morethan desired. In some cases, excess sealant material may separate andbecome foreign object debris. For example, without limitation, when usedinside of a fuel tank, the flow of the fuel within the fuel tank maycause some of the excess sealant material to break apart and formundesired debris within the fuel tank.

With some currently available methods for installing seal caps, excesssealant material that squeezes out of a seal cap may be removed and/orsmoothed by hand. However, this process may be more time-consuming thandesired. When an object comprises multiple fastener elements over whichseal caps are to be installed, the time needed to remove and/or smoothout this excess sealant material may increase production times and/orcosts for the object more than desired. Therefore, it would be desirableto have a method and apparatus that take into account at least some ofthe issues discussed above, as well as other possible issues.

SUMMARY

In one illustrative embodiment, an apparatus may comprise a number ofprojections associated with a structure configured to be positioned overa seal cap that has been adhered and sealed to a fastener element. Thenumber of projections is configured to remove at least a portion ofexcess material around the seal cap when the number of projections ismoved along an interface formed between the seal cap and an object inwhich the fastener element has been installed.

In another illustrative embodiment, a sealant installation system maycomprise a tool and a sealant application device. The tool may comprisea structure and a number of projections associated with the structure.The structure may have a hollow portion configured to receive a seal capin which the hollow portion may extend through the structure to form achannel. The number of projections may be configured to remove at leasta portion of excess material around the seal cap and smooth out anyremaining portion of the excess material when the structure is rotatedabout the seal cap. The sealant application device may be configured forinsertion through the channel of the structure. The sealant applicationdevice may be further configured to inject a material into the seal capwhen the seal cap is positioned over a fastener element. The excessmaterial may be a portion of the material that squeezes out of the sealcap.

In yet another illustrative embodiment, a method for sealing a fastenerelement. A structure may be positioned over a seal cap that has beenadhered and sealed to the fastener element. A number of projectionsassociated with the structure may be moved along an interface formedbetween the seal cap and an object in which the fastener element hasbeen installed such that the number of projections removes at least aportion of excess material around the seal cap while moving along theinterface between the seal cap and the object.

In still yet another illustrative embodiment, a method for sealing afastener element is provided. A seal cap may be adhered to the fastenerelement using a sealant material in which excess sealant materialsqueezes out around the seal cap. A structure may be positioned over theseal cap such that the seal cap is received within a hollow portion ofthe structure. The structure may be rotated about the seal cap such thata number of projections associated with the structure rotates andremoves at least a portion of the excess sealant material around theseal cap and smoothes out any remaining portion of the excess materialas the structure rotates about the seal cap.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a manufacturing environment in the form ofa block diagram in accordance with an illustrative embodiment;

FIG. 2 is an illustration of a top isometric view of a tool inaccordance with an illustrative embodiment;

FIG. 3 is an illustration of a side view of a tool in accordance with anillustrative embodiment;

FIG. 4 is an illustration of an isometric view of a tool with respect toa bottom end of the tool in accordance with an illustrative embodiment;

FIG. 5 is an illustration of sealant material being applied to a sealcap in accordance with an illustrative embodiment;

FIG. 6 is an illustration of a seal cap being placed over a fastenerelement in accordance with an illustrative embodiment;

FIG. 7 is an illustration of a tool being used to remove excess sealantmaterial in accordance with an illustrative embodiment;

FIG. 8 is an illustration of smoothed sealant material around a seal capin accordance with an illustrative embodiment;

FIG. 9 is an illustration of a motorized system for use with a tool inaccordance with an illustrative embodiment;

FIG. 10 is an illustration of a tool being used with a motorized systemin accordance with an illustrative embodiment;

FIG. 11 is an illustration of a sealant application device for use witha tool in accordance with an illustrative embodiment;

FIG. 12 is an illustration of a sealant application device injectingsealant into a seal cap in accordance with an illustrative embodiment;

FIG. 13 is an illustration of a process for installing a seal cap in theform of a flowchart in accordance with an illustrative embodiment;

FIG. 14 is another illustration of a process for installing a seal capin the form of a flowchart in accordance with an illustrativeembodiment;

FIG. 15 is an illustration of an aircraft manufacturing and servicemethod in the form of a block diagram in accordance with an illustrativeembodiment; and

FIG. 16 is an illustration of an aircraft in the form of a block diagramin which an illustrative embodiment may be implemented.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account differentconsiderations. For example, the illustrative embodiments recognize andtake into account that it may be desirable to have a method andapparatus for installing a seal cap over a fastener element that reducesthe overall time needed to install the seal cap. The illustrativeembodiments also recognize and take into account that it may bedesirable to have a tool that may be configured to remove and smooth outexcess sealant material that squeezes out of a seal cap duringinstallation such that the remaining portion of sealant material aroundthe seal cap is of a specified amount and/or a specified thickness.

Referring now to the figures and, in particular, with reference to FIG.1, an illustration of a manufacturing environment is depicted in theform of a block diagram in accordance with an illustrative embodiment.Manufacturing environment 100 is an example of one environment in whichobject 102 may be formed. Object 102 may take a number of differentforms. Object 102 may take the form of, for example, without limitation,a wing box, a spar assembly, a structural frame, or some other type ofobject.

Object 102 may be formed using number of fastener elements 104. As usedherein, a “number of” items may include one or more items. In thismanner, number of fastener elements 104 may include one or more fastenerelements. Number of fastener elements 104 may be installed along anyportion of object 102. Number of fastener elements 104 may include atleast one of a screw, a bolt, a pin, a tie, a clamp, or some other typeof fastener element.

As used herein, the phrase “at least one of,” when used with a list ofitems, may mean different combinations of one or more of the listeditems may be used and only one of the items in the list may be needed.The item may be a particular object, thing, or category. In other words,“at least one of” may mean any combination of items or number of itemsmay be used from the list, but not all of the items in the list may berequired.

For example, “at least one of item A, item B, and item C” may mean itemA; item A and item B; item B; item A, item B, and item C; or item B anditem C. In some cases, “at least one of item A, item B, and item C” maymean, for example, without limitation, two of item A, one of item B, andten of item C; four of item B and seven of item C; or some othersuitable combination.

Number of seal caps 106 may be used to cover and seal number of fastenerelements 104. In particular, a seal cap in number of seal caps 106 maybe used to cover and seal a corresponding fastener element in number offastener elements 104. As one illustrative example, seal cap 108 innumber of seal caps 106 may be used to cover and seal fastener element110 in number of fastener elements 104.

Seal cap 108 may be used to reduce the possibility of any fluid, such asa liquid, air, or some other type of fluid, passing through theinterface between fastener element 110 and object 102. Further, seal cap108 may reduce the possibility of any undesirable material, such as, forexample, without limitation, dirt particles and/or other substances,from passing through the interface between fastener element 110 andobject 102. Additionally, seal cap 108 may also be used to reduce and/orprevent undesired effects resulting from electromagnetic events such as,for example, without limitation, plasma ejections during lightningstrikes and/or other types of electromagnetic events.

In one illustrative example, seal cap 108 may be installed over fastenerelement 110 by applying material 112 over fastener element 110 and thenplacing seal cap 108 over material 112. In some cases, seal cap 108 maybe installed over fastener element 110 by injecting material 112 into ahollow portion of seal cap 108 and then placing seal cap 108 withmaterial 112 inside seal cap 108 over fastener element 110. In thisillustrative example, material 112 may take the form of sealant material113. However, in some cases, material 112 may be an adhesive material orsome other type of material.

Seal cap 108 may be pressed down towards fastener element 110 such thatseal cap 108 adheres to material 112 and, consequently, adheres to andseals fastener element 110 underneath material 112. During this process,excess material 114 may squeeze out and around seal cap 108. Inparticular, excess material 114 may squeeze out along interface 125between seal cap 108 and object 102.

In one illustrative example, seal cap 108 may be considered properlysealed to fastener element 110 and object 102 when excess material 114squeezes out around the entire perimeter of interface 125 between sealcap 108 and object 102. In some cases, seal cap 108 may be consideredproperly sealed to fastener element 110 and object 102 when excessmaterial 114 has a desired thickness and/or extends a desired distancefrom seal cap 108 along interface 125 between seal cap 108 and object102.

Tool 116 may be used to remove at least a portion of excess material 114around seal cap 108. As used herein, “at least a portion” may be some orall of excess material 114. In one illustrative example, tool 116 mayinclude structure 118 and number of projections 120 associated withstructure 118.

As used herein, when one component is “associated” with anothercomponent, this association may be a physical association in thedepicted examples. For example, without limitation, a first component,such as one of number of projections 120, may be considered to beassociated with a second component, such as structure 118, by beingsecured to the second component, bonded to the second component, mountedto the second component, welded to the second component, fastened to thesecond component, and/or connected to the second component in some othersuitable manner. The first component also may be connected to the secondcomponent using a third component. Further, the first component may beconsidered to be associated with the second component by being formed aspart of and/or as an extension of the second component.

Structure 118 may have hollow portion 122. Hollow portion 122 may beconfigured to receive seal cap 108. In particular, structure 118 may beplaced over seal cap 108 such that seal cap 108 may be received withinhollow portion 122 of structure 118.

Number of projections 120 may extend from outer surface 124 of structure118 at and/or near end 126 of structure 118. Number of projections 120may be used to remove at least a portion of excess material 114 aroundinterface 125 between seal cap 108 and object 102. In particular, numberof projections 120 may be moved along interface 125 formed between sealcap 108 and object 102 such that at least a portion of excess material114 around seal cap 108 along interface 125 is removed.

For example, without limitation, structure 118 may be rotated about sealcap 108. In particular, structure 118 may be rotated about axis 121,which may, in turn, cause rotation of number of projections 120associated with structure 118 about axis 121. In one illustrativeexample, axis 121 may be a center axis through structure 118 of tool116. In other illustrative examples, axis 121 may be offset from acenter axis through structure 118. When structure 118 is rotated aboutaxis 121 through structure 118, number of projections 120 may remove atleast a portion of excess material 114 around seal cap 108.

Number of projections 120 may be configured such that the portion ofexcess material 114 left remaining after rotation of structure 118 aboutaxis 121 is a specified amount and/or has a specified thickness, withinselected tolerances. In some cases, one rotation, or turn, of structure118 may result in this specified amount and/or specified thickness ofexcess material 114 being left by number of projections 120.

Each of number of projections 120 may have shape 128 configured suchthat rotation of structure 118 and number of projections 120 allows atleast a portion of excess material 114 to be removed. In some cases,shape 128 of each of number of projections 120 may be configured suchthat some portion of excess material 114 is collected during thisremoval.

In one illustrative example, shape 128 may be a helical shape. Forexample, without limitation, shape 128 of each of number of projections120 may be the shape of a portion of a helix. In another illustrativeexample, shape 128 of each of number of projections 120 may be a curvedshape, such as the curved shape of a propeller blade. Of course, inother illustrative examples, shape 128 of each of number of projections120 may be some other type of curved shape or some other type of shape.

Additionally, during the rotation of structure 118, the portion ofexcess material 114 not removed by number of projections 120 may besmoothed out by number of projections 120. In particular, shape 128 ofeach of number of projections 120 may be configured such that number ofprojections 120 smooth out any remaining portion of excess material 114.By smoothing out the remaining portion of excess material 114, thisremaining portion of excess material 114 may be substantially free ofvoids, open spaces, and/or debris.

Tool 116 may be operated by a human operator, a robotic operator, orsome other type of operator, depending on the implementation. Forexample, without limitation, a human operator may be able to rotatestructure 118 of tool 116 once structure 118 has been placed over sealcap 108. Using tool 116 may allow a human operator better control whensmoothing out excess material 114 as compared to smoothing out excessmaterial 114 by hand, using a flat-edged tool, or some other type oftool.

In one illustrative example, tool 116 may be used with motorized system130. For example, without limitation, tool 116 may be attached tomotorized system 130. In particular, structure 118 may be configured forattachment to motorized system 130. Motorized system 130 may beconfigured to rotate structure 118 when tool 116 is attached tomotorized system 130. In some cases, motorized system 130 may be an endeffector device configured for use with a robotic operator. The roboticoperator may take the form of, for example, without limitation, arobotic arm. Depending on the implementation, motorized system 130 maybe pneumatically powered, electrically powered, or powered in some othermanner.

In one illustrative example, structure 118 may have opening 132. Opening132 may be an opening into hollow portion 122 of structure 118. Opening132 may be configured to receive sealant application device 134. Sealantapplication device 134 may be inserted through opening 132 and passedthrough hollow portion 122 of structure 118. In one illustrativeexample, sealant application device 134 may be an elongate device aroundwhich structure 118 may be positioned.

Sealant application device 134, with structure 118 around sealantapplication device 134, may be used to inject sealant material 113 intoseal cap 108 through corresponding opening 136 in seal cap 108 when sealcap 108 has already been positioned over fastener element 110. Oncesealant application device 134 has finished injecting sealant material113 into seal cap 108 through corresponding opening 136, structure 118may be moved along sealant application device 134 and positioned overseal cap 108 for use in removing at least a portion of excess material114. For example, without limitation, structure 118 may be slid down thelength of sealant application device 134 until structure 118 covers sealcap 108.

In this manner, sealant application device 134 and tool 116 may togetherform seal cap installation system 138 that may be capable of bothinjecting sealant material 113 into seal cap 108 and removing anyundesirable excess sealant material around seal cap 108 along interface125 between seal cap 108 and object 102. In some cases, when motorizedsystem 130 is used to rotate structure 118, motorized system 130 may beconsidered part of seal cap installation system 138.

In this illustrative example, number of projections 120 may be comprisedof any number of materials. Depending on the implementation, each ofnumber of projections 120 may be comprised of at least one of a siliconematerial, a rubber material, a polymer, nylon, plastic, or some othertype of material. The one or more materials out of which number ofprojections 120 may be formed may be selected for the purposes ofsmoothing out excess material 114.

Depending on the implementation, tool 116 may be a disposable tool. Inthis manner, the number of cleanup operations that may need to beperformed and/or the total amount of time needed to seal number offastener elements 104 may be reduced. In some cases, number ofprojections 120 may be removably attached to structure 118. In otherwords, number of projections 120 may be disposable. In some cases,number of projections 120 may be removed from structure 118 such that adifferent set of projections may be used.

The illustration of manufacturing environment 100 in FIG. 1 is not meantto imply physical or architectural limitations to the manner in which anillustrative embodiment may be implemented. Other components in additionto or in place of the ones illustrated may be used. Some components maybe optional. Also, the blocks are presented to illustrate somefunctional components. One or more of these blocks may be combined,divided, or combined and divided into different blocks when implementedin an illustrative embodiment.

With reference now to FIG. 2, an illustration of a top isometric view ofa tool is depicted in accordance with an illustrative embodiment. Inthis illustrative example, tool 200 may be an example of oneimplementation for tool 116 in FIG. 1. In this illustrative example,tool 200 may include structure 202 and number of projections 204.

Number of projections 204 may extend from structure 202 at end 205 ofstructure 202. Structure 202 and number of projections 204 may beexamples of implementations for structure 118 and number of projections120, respectively, in FIG. 1.

As depicted, structure 202 may have hollow portion 206. Hollow portion206 may be an example of one implementation for hollow portion 122 inFIG. 1. In this illustrative example, hollow portion 206 may extendthroughout the entire length of structure 202. In particular, hollowportion 206 may form a channel through structure 202.

Number of projections 204 may include projection 208, projection 210,and projection 212. These projections may extend from outer surface 207of structure 202. Outer surface 207 may be an example of oneimplementation for outer surface 124 in FIG. 1. As depicted, each ofnumber of projections 204 may have shape 214. Shape 214 may be anexample of one implementation for shape 128 in FIG. 1.

In this illustrative example, shape 214 may be a helical shape. Further,shape 214 may be selected such that each of number of projections 204may be capable of removing and collecting excess sealant material. Forexample, without limitation, with shape 214, projection 210 may haveedge 216, first surface 218, and second surface 220.

Edge 216 may have a texture configured to remove material. First surface218 may be configured such that any material removed by edge 216 may becollected on top of first surface 218. Second surface 220 may beconfigured such that any remaining material below second surface 220 issmoothed. For example, without limitation, second surface 220 may be asmooth surface. In some cases, second surface 220 may have a textureconfigured to remove material below second surface 220. For example,without limitation, second surface 220 may have a texture configured toscrape away or pull away material in contact with second surface 220when structure 202 is rotated.

Turning now to FIG. 3, an illustration of a side view of tool 200 fromFIG. 2 is depicted in accordance with an illustrative embodiment. Asdepicted, number of projections 204 may extend past structure 202. Whenused to remove excess material around a seal cap, structure 202 may berotated about axis 300 such that the edge of each of number ofprojections 204 leads. For example, without limitation, structure 202may be rotated about axis 300 such that edge 216 of projection 210 leadsthe rest of projection 210.

With reference now to FIG. 4, an illustration of an isometric view oftool 200 from FIGS. 2-3 is depicted with respect to a bottom end of tool200 in accordance with an illustrative embodiment. In this illustrativeexample, hollow portion 206 of structure 202 may be seen as extendingall the way through structure 202.

Referring now to FIGS. 5-8, illustrations of a process for installing aseal cap over a fastener element are depicted in accordance with anillustrative embodiment. The process illustrated in FIGS. 5-8 may be anexample of one manner in which seal cap 108 in FIG. 1 may be installedover fastener element 110 in FIG. 1. The process illustrated in FIGS.5-8 may be performed using tool 200 from FIGS. 2-4.

With reference now to FIG. 5, an illustration of sealant material beingapplied to a seal cap is depicted in accordance with an illustrativeembodiment. In this illustrative example, number of fastener elements500 may be installed in object 502. Number of fastener elements 500 maybe an example of one implementation for number of fastener elements 104in FIG. 1. Object 502 may be an example of one implementation for object102 in FIG. 1.

As depicted, number of fastener elements 500 may be exposed at surface503 of object 502. Seal cap 504 may be used to cover and seal one ofnumber of fastener elements 500 (not shown in this view). Seal cap 504may be an example of one implementation for seal cap 108 in FIG. 1. Inthis illustrative example, sealant application device 506 may be used toapply sealant material (not shown) inside seal cap 504. Sealantapplication device 506 may be an example of one implementation forsealant application device 134 in FIG. 1. Sealant material (not shown)dispensed from sealant application device 506 may be applied to seal cap504 for use in adhering and sealing seal cap 504 to one of number offastener elements 500.

With reference now to FIG. 6, an illustration of seal cap 504 beingplaced over a fastener element is depicted in accordance with anillustrative embodiment. In FIG. 6, seal cap 504 may be placed over oneof number of fastener elements 500. The particular fastener element maynot be depicted in this view.

When seal cap 504 is placed over this fastener element, excess sealantmaterial 600 may squeeze out of a gap between surface 503 of object 502and seal cap 504. In particular, excess sealant material 600 may squeezeout around and along interface 602 between seal cap 504 and surface 503of object 502. Excess sealant material 600 may be an example of oneimplementation for excess material 114 in FIG. 1.

Excess sealant material 600 around seal cap 504 may be a factor indetermining whether the seal between seal cap 504, object 502, and thefastener element (not shown) underneath seal cap 504 meets selectedrequirements. These selected requirements may be, for example,engineering requirements, assembly requirements, and/or other types ofrequirements.

For example, without limitation, meeting these requirements may requirethat excess sealant material 600 squeezes out around the entireperimeter of interface 602 between seal cap 504 and object 502. In somecases, meeting these requirements may require that excess sealantmaterial 600 have a desired thickness and/or extend a desired distancepast interface 602.

With reference now to FIG. 7, an illustration of tool 200 being used toremove excess sealant material 600 from FIG. 6 is depicted in accordancewith an illustrative embodiment. As depicted, tool 200 may be positionedover seal cap 504.

Structure 202 may be moved in such a manner that causes number ofprojections 204 associated with structure 202 to move along interface602 between seal cap 504 and object 502. In particular, structure 202 oftool 200 may be rotated in the direction of arrow 702 about seal cap504, which may cause rotation of number of projections 204 associatedwith structure 202.

Rotation of structure 202 with structure 202 positioned over seal cap504 may cause at least a portion of excess sealant material 600 to beremoved and/or any remaining portion of excess sealant material 600 notremoved to be smoothed out by number of projections 204. Structure 202may be turned any number of times in the direction of arrow 702,depending on the implementation. In this illustrative example, onecomplete rotation of structure 202 about axis 300 may sufficientlyremove a portion of excess sealant material 600 along interface 602 suchthat the remaining portion of excess sealant material 600 may be of aspecified amount and/or have a specified thickness, within selectedtolerances.

With reference now to FIG. 8, an illustration of smoothed sealantmaterial around seal cap 504 is depicted in accordance with anillustrative embodiment. In this illustrative example, smoothed sealantmaterial 800 may be the remaining portion of excess sealant material 600from FIGS. 6-7 after the rotation of structure 202 of tool 200 withnumber of projections 204 described in FIG. 7.

With reference now to FIG. 9, an illustration of a motorized system foruse with tool 200 from FIGS. 2-4 is depicted in accordance with anillustrative embodiment. In this illustrative example, motorized system900 may be an example of one implementation for motorized system 130 inFIG. 1.

As depicted, motorized system 900 may have retaining structure 902 andlever 904. Retaining structure 902 may be configured to hold tool 200.Lever 904 may be used to cause operation of a motor (not shown in thisview) within motorized system 900. Operation of this motor may causerotation of tool 200, or more specifically, structure 202 of tool 200.

Turning now to FIG. 10, an illustration of tool 200 being used withmotorized system 900 from FIG. 9 is depicted in accordance with anillustrative embodiment. In this illustrative example, number of sealcaps 1000 may be placed over number of fastener elements 500 from FIG. 5(not shown in this view). Tool 200 has been attached to motorized system900 and may be held by retaining structure 902 of motorized system 900.

As depicted, motorized system 900 and tool 200 may be positioned suchthat tool 200 may be placed over seal cap 504. Human operator 1002 mayuse lever 904 to operate the motor (not shown in this view) insidemotorized system 900 to rotate tool 200. In this manner, motorizedsystem 900 may be used to rotate tool 200 to remove at least a portionof excess sealant material 600.

With reference now to FIG. 11, an illustration of a sealant applicationdevice for use with tool 200 from FIGS. 2-4 is depicted in accordancewith an illustrative embodiment. In this illustrative example, sealantapplication device 1100 may be an example of one implementation forsealant application device 134 from FIG. 1. As depicted, sealantapplication device 1100 may be inserted through hollow portion 206 ofstructure 202.

In this illustrative example, sealant application device 1100 mayinclude elongate member 1102 and nozzle tip 1104. Elongate member 1102may be the portion of sealant application device 1100 inserted throughhollow portion 206 of structure 202. Nozzle tip 1104 may be configuredto inject sealant into a seal cap, such as seal cap 504 from FIG. 5.

Turning now to FIG. 12, an illustration of sealant application device1100 from FIG. 11 injecting sealant into seal cap 504 from FIG. 5 isdepicted in accordance with an illustrative embodiment. In thisillustrative example, sealant application device 1100 may be positionedsuch that nozzle tip 1104 from FIG. 4 (not shown in this view) isinserted into an opening (not shown in this view) of seal cap 504.

Sealant material (not shown in this view) may be injected from nozzletip 1104 into seal cap 504 for use in adhering and sealing seal cap 504to the fastener element (not shown in this view) underneath seal cap 504and to object 502. Once the inside of seal cap 504 has been filled withsealant material, tool 200 may be moved relative to sealant applicationdevice 1100. In particular, tool 200 may be slid down sealantapplication device 1100 and positioned over seal cap 504 for use inremoving at least a portion of excess sealant material 600 around sealcap 504.

The illustrations of tool 200 in FIGS. 2-4, the process described inFIGS. 5-8, motorized system 900 in FIGS. 9-10, and sealant applicationdevice 1100 in FIGS. 11-12 are not meant to imply physical orarchitectural limitations to the manner in which an illustrativeembodiment may be implemented. Other components in addition to or inplace of the ones illustrated may be used. Some components may beoptional.

The different components shown in FIGS. 2-12 may be illustrativeexamples of how components shown in block form in FIG. 1 can beimplemented as physical structures. Additionally, some of the componentsin FIGS. 2-12 may be combined with components in FIG. 1, used withcomponents in FIG. 1, or a combination of the two.

With reference now to FIG. 13, an illustration of a process forinstalling a seal cap is depicted in the form of a flowchart inaccordance with an illustrative embodiment. The process illustrated inFIG. 13 may be implemented to install, for example, without limitation,seal cap 108 over fastener element 110 using tool 116 as described inFIG. 1.

The process may begin by adhering and sealing seal cap 108 to fastenerelement 110 using material 112 (operation 1300). In operation 1300,material 112 may be sealant material 113. In one illustrative example,sealant material 113 may be injected into a hollow portion of seal cap108 prior to seal cap 108 being placed over fastener element 110. Inanother illustrative example, sealant material 113 may be applied tofastener element 110 prior to placing seal cap 108 over fastener element110.

During operation 1300, a portion of material 112, which may be excessmaterial 114, squeezes out of seal cap 108 and onto object 102 in whichfastener element 110 has been installed. In particular, excess material114 may squeeze out around and along interface 125 between seal cap 108and object 102. Seal cap 108 may be considered properly sealed tofastener element 110 and object 102 when excess material 114 squeezesout around the entire perimeter of interface 125 between seal cap 108and object 102. In some cases, seal cap 108 may be considered properlysealed to fastener element 110 and object 102 when excess material 114has a desired thickness and/or extends a desired distance from seal cap108 along interface 125 between seal cap 108 and object 102.

Once seal cap 108 has been adhered and sealed to fastener element 110,structure 118 of tool 116 may be positioned over seal cap 108 such thatseal cap 108 is received within hollow portion 122 of tool 116(operation 1302). Structure 118 may have number of projections 120 thatextend from structure 118.

Thereafter, number of projections 120 may be moved along interface 125between seal cap 108 and object 102 such that number of projections 120may remove at least a portion of excess material 114 around seal cap 108along interface 125 and such that any remaining portion of excessmaterial 114 may be smoothed out (operation 1304). Operation 1304 may beperformed by, for example, without limitation, rotating structure 118such that number of projections 120 may be rotated around seal cap 108along interface 125. Tool 116 may then be removed from seal cap 108 tocomplete the installation of seal cap 108 (operation 1306), with theprocess terminating thereafter.

Depending on the implementation, operation 1304 may be performed by ahuman operator, a robotic operator, or some other type of operator. Inone illustrative example, tool 116 may be attached to motorized system130. Motorized system 130 may be used to rotate structure 118. Motorizedsystem 130 may be operable by a human operator or a robotic operator.Depending on the implementation, motorized system 130 may bepneumatically powered, electrically powered, or powered in some othermanner.

The process described in FIG. 13 may be repeated for every seal cap innumber of seal caps 106 in FIG. 1. Using tool 116 to remove excessmaterial 114 around each of number of seal caps 106 may reduce theoverall time and/or cost needed to install number of seal caps 106 overnumber of fastener elements 104 in FIG. 1.

With reference now to FIG. 14, another illustration of a process forinstalling a seal cap is depicted in the form of a flowchart inaccordance with an illustrative embodiment. The process illustrated inFIG. 14 may be implemented to install, for example, without limitation,seal cap 108 over fastener element 110 using tool 116 and sealantapplication device 134 as described in FIG. 1.

The process may begin by positioning seal cap 108 over fastener element110 (operation 1400). Next, sealant application device 134 may beinserted through hollow portion 122 of structure 118 of tool 116 suchthat structure 118 is positioned around some portion of sealantapplication device 134 (operation 1402).

Sealant application device 134 may then be used to inject material 112into seal cap 108 to adhere and seal seal cap 108 to fastener element110 such that fastener element 110 is completely encapsulated by sealcap 108 (operation 1404). In operation 1404, material 112 may causeexcess material 114 to squeeze out of seal cap 108. Material 112 may besealant material 113 and excess material 114 may be an excess portion ofsealant material 113. Seal cap 108 may be considered properly sealed tofastener element 110 and object 102 when the excess portion of sealantmaterial 113 squeezes out around and along interface 125 in a mannerthat meets selected requirements.

Structure 118 may be moved relative to sealant application device 134such that structure 118 may be positioned over seal cap 108 and seal cap108 received within hollow portion 122 of seal cap 108 (operation 1406).Structure 118 with number of projections 120 extending from outersurface 124 of structure 118 may then be rotated such that number ofprojections 120 may remove a portion of excess material 114 alonginterface 125 and such that any remaining portion of excess material 114may be smoothed out (operation 1408). Operation 1408 may be performedsuch that the remaining portion of excess material 114 is of a specifiedamount and/or has a specified thickness, within selected tolerances.Sealant application device 134 and tool 116 may be moved away from sealcap 108 to complete the installation of seal cap 108 (operation 1410),with the process terminating thereafter.

The process described in FIG. 14 may be repeated a number of times toinstall number of seal caps 106 over number of fastener elements 104. Insome cases, all of number of seal caps 106 may be placed over number offastener elements 104 prior to material 112 being injected into each ofnumber of seal caps 106. The process described in FIG. 14 may be used toreduce overall seal cap installation times and/or costs. Further, theprocess described in FIG. 14 may be performed by a human operator and/ora robotic operator, depending on the implementation.

Illustrative embodiments of the disclosure may be described in thecontext of aircraft manufacturing and service method 1500 as shown inFIG. 15 and aircraft 1600 as shown in FIG. 16. Turning first to FIG. 15,an illustration of an aircraft manufacturing and service method in theform of a block diagram is depicted in accordance with an illustrativeembodiment. During pre-production, aircraft manufacturing and servicemethod 1500 may include specification and design 1502 of aircraft 1600in FIG. 16 and material procurement 1504.

During production, component and subassembly manufacturing 1506 andsystem integration 1508 of aircraft 1600 in FIG. 16 takes place.Thereafter, aircraft 1600 in FIG. 16 may go through certification anddelivery 1510 in order to be placed in service 1512. While in service1512 by a customer, aircraft 1600 in FIG. 16 is scheduled for routinemaintenance and service 1514, which may include modification,reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method 1500may be performed or carried out by a system integrator, a third party,and/or an operator. In these examples, the operator may be a customer.For the purposes of this description, a system integrator may include,without limitation, any number of aircraft manufacturers andmajor-system subcontractors; a third party may include, withoutlimitation, any number of vendors, subcontractors, and suppliers; and anoperator may be an airline, a leasing company, a military entity, aservice organization, and so on.

With reference now to FIG. 16, an illustration of an aircraft in theform of a block diagram is depicted in which an illustrative embodimentmay be implemented. In this example, aircraft 1600 is produced byaircraft manufacturing and service method 1500 in FIG. 15 and mayinclude airframe 1602 with plurality of systems 1604 and interior 1606.Examples of systems 1604 include one or more of propulsion system 1608,electrical system 1610, hydraulic system 1612, and environmental system1614. Any number of other systems may be included. Although an aerospaceexample is shown, different illustrative embodiments may be applied toother industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 1500 inFIG. 15. In particular, tool 116 from FIG. 1 may be used for removingexcess sealant material around seal caps during any one of the stages ofaircraft manufacturing and service method 1500. For example, withoutlimitation, tool 116 from FIG. 1 may be used during the installation ofseal caps during at least one of component and subassembly manufacturing1506, system integration 1508, routine maintenance and service 1514, orsome other stage of aircraft manufacturing and service method 1500.

In one illustrative example, components or subassemblies produced incomponent and subassembly manufacturing 1506 in FIG. 15 may befabricated or manufactured in a manner similar to components orsubassemblies produced while aircraft 1600 is in service 1512 in FIG.15. As yet another example, one or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized during productionstages, such as component and subassembly manufacturing 1506 and systemintegration 1508 in FIG. 15. One or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized while aircraft1600 is in service 1512 and/or during maintenance and service 1514 inFIG. 15. The use of a number of the different illustrative embodimentsmay substantially expedite the assembly of and/or reduce the cost ofaircraft 1600.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent a module, a segment, a function, and/or a portionof an operation or step.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be executed substantially concurrently, or the blocks maysometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different illustrativeembodiments may provide different features as compared to otherdesirable embodiments. The embodiment or embodiments selected are chosenand described in order to best explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A method for sealing a fastener element, themethod comprising: rotating a structure about a seal cap that has beenadhered and sealed to the fastener element; and moving a number ofprojections associated with the structure along an interface formedbetween the seal cap and an object in which the fastener element hasbeen installed such that the number of projections removes at least aportion of excess material around the seal cap while moving along theinterface between the seal cap and the object.
 2. The method of claim 1,wherein moving the number of projections comprises: rotating thestructure about the seal cap using a motorized system such that thenumber of projections associated with the structure is rotated.
 3. Themethod of claim 1, wherein rotating the structure about the seal capcomprises: rotating the structure about a center axis of the seal capsuch that the number of projections associated with the structure arerotated around the seal cap along the interface between the seal cap andthe object.
 4. A method for sealing a fastener element, the methodcomprising: squeezing out excess sealant material around a seal cap;positioning a structure over the seal cap such that the seal cap isreceived within a hollow portion of the structure; and rotating thestructure about the seal cap such that a number of projectionsassociated with the structure rotates and removes at least a portion ofthe excess sealant material around the seal cap and smooths out anyremaining portion of the excess material as the structure rotates aboutthe seal cap.
 5. The method of claim 4 further comprising: adhering theseal cap to the fastener element using the sealant material.
 6. A methodfor sealing a fastener element, the method comprising: rotating astructure about a seal cap that has been sealed to the fastener element;moving a number of projections associated with the structure along aninterface formed between the seal cap and an object in which thefastener element has been installed; and removing at least a portion ofexcess material around the seal cap while moving the number ofprojections along the interface between the seal cap and the object.